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United States Patent |
5,712,071
|
Mikuriya
,   et al.
|
January 27, 1998
|
Toner for developing electrostatic latent image
Abstract
A toner produced by pulverizing and classifying a melt and kneaded mixture
comprising a binder resin, a colorant and an offset preventing agent, said
binder resin comprising a styrene-type copolymer and said offset
preventing agent comprising a polypropylene having a softening point of
135.degree. to 155.degree. C. and a polyethylene having a softening point
of 100.degree. to 150.degree. C., wherein a total amount of said
polypropylene and said polyethylene is 2 to 10 parts by weight per 100
parts by weight of the binder resin and a weight ratio of said
polypropylene to said polyethylene is 1:3 to 1:1, and said pulverizing and
classifying carried out by a pulverizer and classifier which impart
mechanical impact on a particle to be treated.
Inventors:
|
Mikuriya; Yoshihiro (Amagasaki, JP);
Sukeno; Mikihiko (Ashiya, JP);
Nishihara; Yoshikazu (Itami, JP);
Fukuda; Hiroyuki (Kobe, JP)
|
Assignee:
|
Minolta Co., Ltd. (Osaka, JP)
|
Appl. No.:
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543587 |
Filed:
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October 16, 1995 |
Foreign Application Priority Data
Current U.S. Class: |
430/108.8; 430/109.3; 430/111.4 |
Intern'l Class: |
G03G 009/097 |
Field of Search: |
430/110,111
|
References Cited
U.S. Patent Documents
4355088 | Oct., 1982 | Westdale et al. | 430/98.
|
4386147 | May., 1983 | Seimiya et al. | 430/99.
|
4486524 | Dec., 1984 | Fujisaki et al. | 430/129.
|
4578338 | Mar., 1986 | Gruber et al. | 430/120.
|
4604338 | Aug., 1986 | Gruber et al. | 430/110.
|
4917982 | Apr., 1990 | Tomono et al. | 430/99.
|
4939060 | Jul., 1990 | Tomiyama et al. | 430/106.
|
4946755 | Aug., 1990 | Inoue | 430/106.
|
4971882 | Nov., 1990 | Jugle | 430/110.
|
4988598 | Jan., 1991 | Tomono et al. | 430/99.
|
4997739 | Mar., 1991 | Tomono et al. | 430/110.
|
5004666 | Apr., 1991 | Tomono et al. | 430/110.
|
5023158 | Jun., 1991 | Tomono et al. | 430/99.
|
5106715 | Apr., 1992 | Matsumura et al. | 430/110.
|
5124224 | Jun., 1992 | Burkes et al. | 430/110.
|
5171653 | Dec., 1992 | Jugle et al. | 430/108.
|
5176978 | Jan., 1993 | Kumashiro et al. | 430/110.
|
5278018 | Jan., 1994 | Young | 430/106.
|
5292609 | Mar., 1994 | Yoshkawa et al. | 430/110.
|
5466555 | Nov., 1995 | Taguchi et al. | 430/110.
|
Primary Examiner: Martin; Roland
Claims
What is claimed is:
1. A toner for developing an electrostatic latent image comprising:
a binder resin comprising a first copolymer having a number average
molecular weight of 2,000 to 20,000 and a second copolymer having a number
average molecular weight of 50,000 to 500,000, wherein a total amount of
said first and said second copolymer is 70 percent by weight or more on a
basis of the binder resin, said first and said second copolymer
respectively comprising styrene copolymer or styrene derivative copolymer;
a colorant; and
an offset preventing agent comprising a polypropylene having a softening
point of 135.degree. C. to 155.degree. C. and a polyethylene having a
softening point of 100.degree. C. to 150.degree. C., wherein a total
amount of said polypropylene and said polyethylene is 2 to 10 parts by
weight per 100 parts by weight of the binder resin and a weight ratio of
said polypropylene to said polyethylene is 1:6 to 1:1.
2. The toner as claimed in claim 1 wherein the weight ratio of the
polypropylene to the polyethylene is 1:3 to 1:1.
3. The toner as claimed in claim 1 wherein the softening point of the
polypropylene is higher than the softening point of the polyethylene.
4. The toner as claimed in claim 1 wherein the amount of said offset
preventing agent is in the range of 2 to 5 parts by weight per 100 parts
by weight of the binder resin.
5. The toner as claimed in claim 1 which further comprises a charge
controlling agent.
6. The toner as claimed in claim 5 wherein said charge controlling agent is
at least one compound selected from the group consisting of nigrosine dyes
and imidazole compounds.
7. The toner as claimed in claim 6 wherein said charge controlling agent is
contained in an amount of 2 to 7 percent by weight on the basis of the
toner.
8. The toner as claimed in claim 6 which further comprises a quaternary
ammonium salt.
9. The toner as claimed in claim 8 wherein said quaternary ammonium salt is
contained in an amount of 0.1 to 1.5 percent by weight on the basis of the
toner.
10. The toner as claimed in claim 1 which further comprises a magnetic
powder, said magnetic powder contained in an amount of 0.5 to 10 percent
by weight on the basis of the toner.
11. The toner as claimed in claim 1 which further comprises at least one
fluidizing agent selected from the group consisting of hydrophobic silica,
hydrophobic titania and hydrophobic alumina, said fluidizing agent
externally added to the toner.
12. The toner as claimed in claim 11 which further comprises a fine resin
particle made of a compound selected from the group consisting of
fluororesins and acrylic resins, said fine resin particle externally added
to the toner together with the fluidizing agent.
13. The toner as claimed in claim 1 wherein said first copolymer is
contained in an amount of 10 to 70 parts by weight per 100 parts by weight
of the binder resin.
14. The toner as claimed in claim 13 wherein the amount of said first
copolymer is 20 to 50 parts by weight per 100 parts by weight of the
binder resin.
15. A toner for developing an electrostatic latent image comprising:
a binder resin comprising a copolymer having peaks in a molecular weight
distribution chromatogram measured by gel permeation chromatography,
wherein a first peak is in a range of 2,000 to 20,000 and a second peak is
in a range of 50,000 to 500,000 and a total amount of said copolymer is 70
percent by weight or more on the basis of the binder resin, said copolymer
comprising styrene copolymer or styrene derivative copolymer;
a colorant; and
an offset preventing agent comprising a polypropylene having a softening
point of 135.degree. C. to 155.degree. C. and a polyethylene having a
softening point of 100.degree. C. to 150.degree. C., wherein a total
amount of said polypropylene and said polyethylene is 2 to 10 parts by
weight per 100 parts by weight of the binder resin.
16. The toner as claimed in claim 15 wherein said copolymer is synthesized
with at least one monomer selected from the group consisting of a styrene
monomer and a styrene derivative monomer and a comonomer, wherein said
monomer is contained in an amount of 50 percent by weight on the basis of
a total amount of said monomer and comonomer.
17. The toner as claimed in claim 16 wherein said monomer is at least one
compound selected from the group consisting of a styrene,
.alpha.-methylstyrene, p-methylstyrene and p-chlorostyrene.
18. The toner as claimed in claim 16 wherein said comonomer is at least one
compound selected from the group consisting of unsaturated carboxylic
acid, alkyl acrylates having 1 to 17 carbon atoms in their alkyl group and
alkyl methacrylates having 1 to 17 carbon atoms in their alkyl group.
19. The toner as claimed in claim 15 which contains the polypropylene less
than the polyethylene.
20. The toner as claimed in claim 19 which has a weight ratio of the
polypropylene to the polyethylene in the range of 1:3 to 1:1.1.
21. The toner as claimed in claim 18 wherein said copolymer has an acid
value of 1 to 15 KOHmg/g.
22. The toner as claimed in claim 21 wherein the acid value of the
copolymer is 3 to 10 KOHmg/g.
23. The toner as claimed in claim 15 wherein said first peak is in the
range of 3,000 to 18,000 and said second peak is in the range of 80,000 to
500,000.
24. A toner for developing an electrostatic latent image, wherein said
toner is produced by a process comprising steps of:
melting and kneading a mixture comprising a binder resin, a colorant and an
offset preventing agent, said binder resin comprising
copolymer having peaks in a molecular weight distribution chromatogram
measured by gel permeation chromatography, wherein a first peak is in a
range of 2,000 to 20,000 and a second peak is in a range of 50,000 to
500,000, said copolymer comprising styrene copolymer or styrene derivative
copolymer, and said offset preventing agent comprising a polypropylene
having a softening point of 135.degree. C. to 155.degree. C. and a
polyethylene having a softening point of 100.degree. C. to 150.degree. C.,
wherein a total amount of said polypropylene and said polyethylene is 2 to
10 parts by weight per 100 parts by weight of the binder resin;
cooling the melted and kneaded mixture;
first, pulverizing the cooled mixture into a coarse pulverized mixture;
second, pulverizing the coarse pulverized mixture into a finely pulverized
mixture by passing the coarse pulverized mixture through a zone under
dispersed conditions in a flowing air stream, said zone being formed
between a rotating member and a fixed member; and
classifying the finely pulverized mixture to obtain the toner.
25. The toner as claimed in claim 24 wherein said copolymer comprises a
first copolymer having a peak of the molecular weight distribution in a
range of 2,000 to 20,000 and a second copolymer having a peak of the
molecular weight distribution in a range of 50,000 to 500,000, said first
copolymer contained in an amount of 20 to 50 parts by weight per 100 parts
by weight of the binder resin.
26. The toner as claimed in claim 24 wherein said copolymer has an acid
value of 1 to 15 KOHmg/g.
27. The toner as claimed in claim 24 wherein said pulverizer has a rotating
member for pulverization and carries out the pulverization by the impact
of said rotating member against the toner.
28. A toner for developing an electrostatic latent image comprising:
a binder resin comprising a first polymer and a second polymer having a
number average molecular weight greater than that of said first polymer,
said first and said second polymer respectively comprising styrene polymer
or styrene derivative polymer, said first polymer having a number average
molecular weight of 2,000 to 20,000 and said second polymer having a
number average molecular weight of 50,000 to 500,000;
a colorant; and
an offset preventing agent comprising a polypropylene having a softening
point of 135.degree. C. to 155.degree. C. and a polyethylene having a
softening point of 100.degree. C. to 150.degree. C.
29. The toner as claimed in claim 28 wherein said first and second polymer
are copolymer synthesized with at least one monomer selected from the
group consisting of a styrene monomer and a styrene derivative monomer and
a comonomer.
30. The toner as claimed in claim 29 wherein a total amount of said first
and second copolymer is 70 percent by weight or more on the basis of the
binder resin.
31. The toner as claimed in claim 28 wherein a total amount of said
polypropylene and said polyethylene is in the range of 2 to 10 parts by
weight per 100 parts by weight of the binder resin.
32. The toner as claimed in claim 28 wherein a weight ratio of said
polypropylene to said polyethylene is in the range of 1:6 to 1:1.
33. A toner for developing an electrostatic latent image comprising:
a binder resin comprising a first copolymer having a number avenge
molecular weight of 2,000 to 20,000 and a second copolymer having a number
average molecular weight of 50,000 to 500,000, wherein a total amount of
said first and second copolymer is 70 percent by weight or more on the
basis of the binder resin, said first and said second copolymer
respectively comprising
styrene copolymer or styrene derivative copolymer;
a black colorant; and
an offset preventing agent comprising a polypropylene having a softening
point of 135.degree. C. to 155.degree. C. and a polyethylene having a
softening point of 100.degree. C. to 150.degree. C., wherein a total
amount of said polypropylene and said polyethylene is 2 to 10 parts by
weight per 100 parts by weight of the binder resin and a weight ratio of
said polypropylene to said polyethylene is 1:6 to 1:1.
34. The toner as claimed in claim 33, wherein said black colorant comprises
carbon black.
35. A toner for developing an electrostatic latent image comprising:
a binder resin comprising at fist polymer and a second polymer having a
number average molecular weight greater than that of said first polymer,
said first and said second polymer respectively comprising styrene polymer
or styrene derivative polymer said first polymer having a number average
molecular weight of 2,000 to 20,000 and said second polymer having a
number average molecular weight of 50,000 to 500,000;
a colorant; and
an offset preventing agent comprising a polypropylene having a softening
point of 135.degree. C. to 155.degree. C. and a polyethylene having a
softening point of 100.degree. C. to 150.degree. C., an amount of said
polypropylene being less than that of said polyethylene.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a toner for developing electrostatic
latent images.
2. Description of the Related Art
Copy images produced by electrophotographic copying are obtained by
performing an electrostatic latent image forming process by charging and
optically exposing an electrostatic latent image-carrying member,
developing process to develop the electrostatic latent image, and transfer
process to transfer the toner image obtained by the developing process
onto a copy sheet, and thereafter fixing the transferred toner image onto
the copy sheet in a final process.
The fixing process is typically accomplished by methods wherein a heating
roller is brought into direct pressure contact with the toner image (heat
roll fixing method), or a heating member makes pressure contact with the
toner image through a film (partial heat fixing method), and like methods.
In these fixing methods, a part of the toner fused during fixing adheres
to the fixing roller or film, so as to cause a so-called offset phenomenon
when the toner is transferred onto the next copy sheet during a subsequent
fixing process.
An example of the art of preventing offset phenomenon is disclosed in
Japanese Laid-Open Patent Application No. SHO49-65231, which describes a
toner comprising styrene-type resin and polypropylene wax as an offset
preventing agent.
When, however, a copying sheet having an image produced by copying using
the above-mentioned toner is used as an original document and placed in an
automatic document feeder of a copying machine and copied, the copy image
of the original document is rubbed by the sheet feeding roller of the
document feeder, which causes marring and soiling of the image. In the
case of duplex copies and multi-color copies, the copy image surface is
rubbed by the sheet feeding roller during the second copy process, which
also causes marring and soiling of the image. The same phenomenon occurs
when a plurality of copy images are stacked and temporarily held in the
copying machine as they are fed by the sheet feeding roller for the second
copy, thereby reducing image quality. Toners having the above-mentioned
disadvantages are called "poor smear resistance".
Deterioration of toner smear resistance can be prevented by using
polyethylene wax instead of polypropylene wax as an offset preventing
agent. Toners containing polyethylene wax have poor heat resistance,
however.
On the other hand, toner is generally manufactured by melting and kneading
the constituent materials, and thereafter pulverizing the melt and kneaded
material by a pulverizer, and classifying the pulverized material by a
classifying device. A jet pulverizer is used in the pulverization process
to pulverize the particles via impact with an impact plate. An air
classifying device is typically used in the classification process to
classify the particles by size using an airflow.
Toner pulverized by the jet pulverizer and classified by an air classifying
device has the disadvantage of having ultra fine toner powder mixed in,
which leads to toner airborne dispersion and toner scattering and the
like.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a toner having excellent
characteristics not previously obtained.
Another object of the invention is to provide a toner having excellent
smear resistance characteristics.
A further object of the invention is to provide a toner having excellent
offset resistance characteristics.
A still further object of the invention is to provide a toner which does
not produce toner airborne dispersion nor scattering.
Another object of the invention is to provide a toner which does not cause
image fog.
Another object of the invention is to provide a toner having excellent heat
resistance.
These and other objects, advantages and features of the present invention
will become apparent from the following description thereof taken in
conjunction with the accompanying drawings which illustrate specific
embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following description, like parts are designated by like reference
numbers throughout the several drawings.
FIG. 1 briefly shows the construction of an example of an impact pulverizer
using a high-speed airflow;
FIG. 2 shows an example of a classification device provided with a
classification rotor as viewed in vertical center cross section;
FIG. 3 shows a horizontal section view of the classification portion of the
classification device of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The toner of the present invention comprises at least a combination of
binder resin having as its main constituent a styrene-type polymer,
colorant, and specific offset preventing agent.
It is desirable that styrene-type copolymer is used as a styrene-type
polymer. In the present invention, styrene-type copolymer means a polymer
synthesized with a styrene-type monomer and a comonomer. A styrene-type
monomer ratio of the styrene-type copolymer is at least 50
percent-by-weight, and preferably 60 percent-by-weight or more, and
ideally 70 percent-by-weight or more on the basis of total monomers.
A styrene-type monomer ratio of less than 50 percent-by-weight may cause
reduction of powder properties such as heat resistance, flow
characteristics, flocculation resistance and the like.
Examples of useful styrene-type monomers for producing the styrene-type
copolymer include styrene, and derivatives thereof including
.alpha.-methylstyrene, p-methylstyrene, p-chlorostyrene and the like. It
is desirable that styrene be used.
Examples of comonomers useful for copolymerization with styrene-type
monomers include alkyl acrylates, alkyl methacrylates, acrylonitrile,
maleic acid, maleic acid ester, methacrylate, acrylic acid, vinyl
chloride, vinyl benzoate, vinylmethyl ketone, vinylhexyl ketone,
vinylmethyl ether, vinylethyl ether, vinylisobutyl ether and like vinyl
monomers. It is desirable that the alkyl acrylates used have 1.about.17
carbon atoms in the alkyl group, and the alkyl methacrylates used have
1.about.17 carbon atoms in the alkyl group. It is further desirable that
the alkyl acrylates, or alkyl methacrylates be used in combination with
unsaturated carboxylic acids such as acrylic acid, methacrylic acid, and
maleic acid.
The toner binder resin is desirably a mixture of a first styrene-type
copolymer having a number average molecular weight of 2,000.about.20,000
and preferably 5,000.about.15,000, and a second styrene-type copolymer
having a number average molecular weight of 5,000.about.500,000 and
preferably 100,000.about.400,000. The first styrene-type copolymer is
desirably used at a rate of 10.about.70 parts-by-weight, preferably
20.about.50 parts-by-weight and more preferably 30.about.50
parts-by-weight. The second styrene-type copolymer is desirably used at a
rate of 30.about.90 parts-by-weight, preferably 50.about.80
parts-by-weight and more preferably 50.about.70 parts-by-weight. Thus,
when a plurality of styrene-type copolymers having different number
average molecular weights are used, superior results are obtained relative
to offset resistance, coiling resistance, toner charge buildup, and toner
strength by the high molecular weight constituents, and excellent fixing
characteristics are obtained by the low molecular weight styrene-type
copolymer constituents.
When the mixture content is such that it contains the high molecular weight
styrene-type copolymer constituent more than the low molecular weight
styrene-type copolymer constituent, the toner charge buildup becomes
smoother and fewer ultra fine powder is produced when manufacturing the
toner by pulverization.
Reduction of toner fixing characteristics can be suppressed even when the
amount of the high molecular weight styrene-type copolymer constituent is
plentiful by using a styrene-type copolymer having a number average
molecular weight of 2,000.about.20,000 as a low molecular weight
constituent.
The number average molecular weights of styrene-type copolymers can be
calculated as a molecular weight at the position of peak in a molecular
weight distribution chromatogram measured by gel permeation chromatography
(GPC).
A styrene-type copolymer having an acid value of 1.about.15 KOHmg/g, and
preferably 3.about.10 KOHmg/g, is used in consideration of the
stabilization of toner charge.
The various styrene-type copolymers used in the binder resin described
above can be manufactured by well known methods. For example, suspension
polymerization, emulsion polymerization, solution polymerization, bulk
polymerization and the like.
Adjustment of the molecular weight of the styrene-type copolymers can be
achieved using well known molecular weight regulating agents such as, for
example, mercaptans such as lauryl mercaptan, phenyl mercaptan, butyl
mercaptan, dodecyl mercaptan and the like, and halogenated carbons such as
carbon tetrachloride, carbon tetrabromide and the like.
Although the styrene-type copolymer may contain constituents which are
insoluble in tetrahydrofuran (THF) by using crosslinking agents such as
divinylbenzene and the like, it is preferable that it not contain
THF-insoluble constituents.
Other common resins may be mixed with the styrene-type copolymers. For
example, polyester resin, epoxy resin, silicone resin, polystyrene resin,
polyamide resin, polyurethane resin, acrylic resin and the like may be
mixed therewith. It is desirable that the amount of said additional resins
does not exceed 30 percent-by-weight of the total resin.
The offset preventing agents used in combination with the styrene-type
copolymer are polyethylene wax and polypropylene wax.
Usable polypropylene waxes have a softening point of
135.degree..about.155.degree. C., so as to be consistent with desired heat
resistance and offset resistance. When a wax having a softening point less
than 135.degree. C. is used, high temperature offset may occur, and toner
heat resistance may be reduced. When a wax having a softening point
greater than 155.degree. C. is used, fixing strength may be reduced.
Usable polyethylene waxes have a softening point of
100.degree..about.150.degree. C., and preferably
120.degree..about.150.degree. C., so as to be consistent with desired
toner particle characteristics and offset resistance. When a wax having a
softening point lower than 100.degree. C. is used, toner particle
characteristics may be reduced, and when a wax having a softening point
higher than 150.degree. C. is used, high temperature offset may occur.
In the present invention, the softening point of polypropylene wax is a
value obtained by a method stipulated in Japanese Industrial Standard JIS
K2531-1960. Furthermore, the softening point of polyethylene wax is a
value obtained by a method stipulated in Japanese Industrial Standard JIS
K-2207.
The percentage of polypropylene wax (PP) to polyethylene wax (PE) expressed
as a weight ratio is desirably 1:6.about.1:1 (PP:PE), preferably
1:3.about.1:1, and ideally 1:3.about.1:1.1. When the percentage of
polyethylene was is excessive, heat resistance problems may arise, whereas
smearing problems may be unresolved if the percentage is too low.
The total amount of included polypropylene wax and polyethylene wax
relative to 100 parts binder resin is desirably 2.about.10
parts-by-weight, and preferably 2.about.5 parts-by-weight. When the total
amount of said waxes is less than 2 parts-by-weight, the width of the
toner non-offset range may be narrowed and offset may occur. When the
total amount of waxes is greater than 10 parts-by-weight, toner particle
characteristics and heat resistance may be reduced.
Various common types of colorants may be added to the toner, such as, for
example, carbon black.
In addition to binder resins, colorants, and offset preventing agents,
other additives such as, for example, charge controlling agents and
magnetic powders and the like may be added as desired.
Toner may be manufactured by melting and kneading binder resin containing
styrene-type copolymer, offset preventing agent comprising a mixture of
polyethylene and polypropylene, colorant and desired additives as
necessary, and pulverizing and classifying the obtained kneaded mixture.
At this time, it may be convenient to coarsely pulverize the kneaded
material in conjunction with the subsequent pulverization process to
obtain a coarsely pulverized material having a mean particle size of
0.5.about.5 mm, then finely pulverizing the coarse material to obtain
particles having a mean particle size of 10.about.19 .mu.m.
In the pulverization and classification processes, said pulverization and
classification is preferably accomplished by pulverizer and classifier
devices provided with a high-speed rotation rotor and having a function
for imparting a mechanical impact force. This mechanical impact force is a
physical impact force produce by contact of the particles with the
high-speed rotation rotor provided in the pulverizer and classifier
devices. Use of such pulverizer and classifier devices prevents production
of ultra fine powder, stabilizes toner charging characteristics, and
improves flow characteristics.
Specifically, the mechanical impact force may be achieved by impact
pulverization methods, and preferably by high-speed airflow impact
pulverization methods. Similar effect can be achieved using a vortex
airflow generated between a rotor and an exterior liner via high speed
rotation of the rotor. Although it is possible to accomplish the impact
force by jet pulverization using an ultra high-speed airflow from a jet
nozzle, power costs are markedly higher than impact pulvurization methods.
Efficient particle formation can be particularly achieved by high-speed
airflow impact pulverization.
Although commonly used impact type pulverizers may be used as a pulverizer
suitable for imparting mechanical impact force, Criptron system (Kawasaki
Heavy Industries, Ltd.) utilizing a high-speed airflow impact
pulverization method is particularly desirable.
The construction of the criptron system is briefly shown in FIG. 1. The
rotation unit comprises rotor 1 having multiple channels formed thereon,
and the interior surface of the casing has stators mounted thereon which
have multiple channels. A strong vortex and pressure oscillation are
generated within the device by high-speed rotation of rotor 1. Raw
materials are supplied into a pulverization chamber by an atmospheric
airflow via intake port 3. Pulverization occurs via the strong airflow
vortex, and particles rise in rotation with the rotor, and are discharged
with air via exhaust port 4.
The ultra fine powder mixed with the raw materials and ultra fine powder
produced during pulverization can be incorporated and fixed to the surface
of the pulverized particles via the mechanical impact force at the same
time the raw material is pulverized using the above-mentioned device.
Pulverized particles obtained in this manner has a very slight percentage
of ultra fine powder content among the particles.
When the pulverized particles obtained in the manner described above are
pulverized to small size particles (mean particle size: 5.about.10 .mu.m),
the jet airflow type pulverization method may be used. Jet airflow
pulverization methods accelerate particles via a high-speed airflow so as
to strike an impact plate, or pulverize particles by causing the particles
to strike on another.
Conventional jet airflow type pulverizers may be used as the jet airflow
pulverizing device. Such conventional devices include, for example, the
jet pulverizer (Jet Mill model I; Japan Pneumatic Industries, Ltd.), and
the counter jet mill (Hosokawa Micron, Ltd.) and the like.
Finally, the obtained fine particles are classified. It is desirable that
classification also be accomplished using a classifying device utilizing a
mechanical impact force; a rotor type classification unit may be used. The
classification process smoothes the surface of the particles via the
action of the impact force imparted by the rotor so as to produce
spherical particles. Furthermore, free ultra fine powder is reduced
because the ultra fine powder is strongly adhered to and embedded in the
surface of the toner particles, thereby improving dispersion efficiency
via the impact force of the classifying rotor, preventing mixing of ultra
fine powder in the final toner product, and preventing the presence of
free charge controlling agent by the same principles. Similar effects are
not accomplished by conventional air classification devices which use the
relative weight of particles for classification.
Desirable models of rotor type classification devices include various known
types of devices, for example, Turbo Classifier (Nisshin Engineering
Ltd.), Accucut (Japan Donaldson, Ltd.). Among such devices, the T-plex
Fine Powder Classifier 100.about.1,000 ATP Series (Hosokawa Micron, Ltd.)
is desirable. From this series of devices, the construction of the T-plex
Multiwheel classifier is briefly shown in FIGS. 2 and 3. FIG. 2 is a
center vertical section view, and FIG. 3 is a horizontal section view of
the classifying unit.
Raw materials (small particles) are loaded from material loading port 12,
and carried into a classifying chamber together with intake air or through
a rotary valve. Intake air flows within the device, for example, from
bottom to top as indicated by the arrow. Raw materials rises in accordance
with the airflow, and enters classifying unit 11 for classification, and
fine powder is removed through common discharge port 13. Classifying unit
11 has a plurality of individual classifying rotors mounted horizontally
and are individually driven. A common speed controller controls the speeds
of said rotors through a single frequency converter. The removed fine
powder classified material is eliminated from discharge port 14. The raw
material comprising small size particles may be air classified prior to
being supplied to the rotor type classification device.
The above-mentioned toner is suitable for use as a positive charging toner,
because styrene-type copolymer is used as the previously mentioned binder
resin. For example, use of polyester resin as the binder resin is
undesirable because the polyester resin itself essentially has negative
charging characteristics which prevent suitable positive charging. It is
also desirable to use a positive charging toner which contains a positive
charge controlling agent such as nigrosine dyes, imidazole compounds and
the like; the amount of such additive is preferably 2.about.7
percent-by-weight relative to the toner. It is further desirable to add
0.1.about.1.5 percent-by-weight of quaternary ammonium salt with the
aforesaid positive charge controlling agent to stabilize the amount of
toner charge.
A slight amount of magnetic powder may be added to the toner at a rate of
0.5.about.10 percent-by-weight to prevent toner dispersion.
Hydrophobic silica, hydrophobic titania, or hydrophobic alumina or like
fluidizing agent may be added to the toner at a rate of 0.05.about.1.5
percent by-weight relative to the toner. Furthermore, fine resin particles
of fluororesin such as tetrafluoroethylene polymer, acrylic resin or the
like may be added to prevent Wear of the cleaning blade.
The present invention is applicable to various types of toners, e.g.,
two-component toners, monocomponent toners, magnetic toners and the like,
which are manufactured by pulverization and classification.
Specific experimental examples of the toner of the present invention are
described hereinafter.
EXAMPLE 1
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(pbw = parts-by-weight)
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* Thermoplastic styrene-acrylic resin
100 pbw
›Containing 35 pbw styrene-butylacrylate-
butylmethacrylate-methacrylic acid copolymer having
a number average molecular weight of 5,000 deter-
mined by gel permeation chromatography (GPC)
(monomer weight ratios = 7:1.4:1.4:0.2; acid value:
6.5 KOH mg/g) and 65 pbw styrene-butylacrylate-
butylmethacrylate-methacrylic acid copolymer having
a number average molecular weight of 200,000
measured by GPC (monomer weight ratio =
6:1.9:1.9:0.2; acid value: 6.5 KOH mg/g)!
* Polypropylene wax 1.0 pbw
(Biscol 660P; Sanyo Chemical Industries, Ltd.,
softening point about 145.degree. C.)
* Polyethylene wax 2.0 pbw
(High Wax 200P; Mitsui Sekiyu Kagaku K.K.,
softening point about 120.degree. C.)
* Carbon black 10 pbw
(Mogal L; Cabot, Inc.)
* Nigrosine dye 5.0 pbw
(Nigrosine Base EX; Oriental Chemicals, Inc.)
* Quaternary Ammonium Salt 0.5 pbw
(P-53; Orient Chemical, Inc.)
* Magnetic powder 2 pbw
(Zinc ferrite)
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The above-mentioned materials were loaded in a Henschel mixer (9 liter
capacity) and mixed for 3 minutes at 3,000 rpm. The mixture was then
kneaded by continuous extrusion kneader model PCM 30 (1/d=32.5).
After the kneaded material cooled, it was coarsely pulverized by a feather
mill (2 mm mesh). The coarsely pulverized material was then finely
pulverized to a particle size of 11 .mu.m by a mechanical pulverizer
(Model Criptron KTM-0; Kawasaki Heavy Industries, Ltd.), coarse particles
were separated by a natural airflow type classifier (DS classifier; Japan
Pneumatic, Ltd.), and finally fine particles were separated by a
mechanical classifier (50ATP Classifier; Hosokawa Micron, Ltd.) to obtain
a toner having a mean particle size of 11 .mu.m.
To the obtained toner were added 0.15 percent-by-weight hydrophobic silica
(R-974; Nippon Aerosil Ltd.) 0.03 percent-by-weight teflon beads (Central
Glass, Ltd.).
EXAMPLE 2
A toner was produced in the same manner as described in Example 1 with the
exception that 100 pbw of the thermoplastic styrene acrylic resin used
comprised 60 pbw styrene-butylacrylate-butylmethacrylate-methacrylic acid
copolymer having a number average molecular weight of 5,000 measured by
GPC (monomer weight ratios=7:1.4:1.4:0.2; acid value: 6.5 KOHmg/g) and 40
pbw of styrene-butylacrylate-butylmethacrylate-methacrylic acid copolymer
having a number average molecular weight of 200,000 measured by GPC
(monomer weight ratios=6:1.9:1.9:0.2; acid value: 6.5 KOHmg/g), with only
3.0 pbw polypropylene wax (softening point about 145.degree. C.; Biscol
660P; Sanyo Chemicals Ltd.) added as an offset preventing agent.
EXAMPLE 3
A toner was produced in the same manner as described in Example 1 with the
exception that 100 pbw of the thermoplastic styrene acrylic resin used
comprised 47 pbw styrene-butylacrylate-methacrylic acid copolymer having a
number average molecular weight of 15,000 measured by GPC (monomer weight
ratios=7:2.8:0.2; acid value: 6.5 KOHmg/g) and 53 pbw of
styrene-butylacrylate-methacrylic acid copolymer having a number average
molecular weight of 350,000 measured by GPC (monomer weight
ratios=6:3.8:0.2; acid value: 6.5 KOHmg/g).
EXAMPLE 4
A toner was produced in the same manner as described in Example 1 with the
exception that 100 pbw of the thermoplastic styrene acrylic resin used
comprised 60 pbw styrene-butylacrylate-methacrylic acid copolymer having a
number average molecular weight of 15,000 measured by GPC (monomer weight
ratios=7:2.8:0.2; acid value: 6.5 KOHmg/g) and 40 pbw of
styrene-butylacrylate-methacrylic acid copolymer having a number average
molecular weight of 350,000 measured by GPC (monomer weight
ratios=6:3.8:0.2; acid value: 6.5 KOHmg/g), with only 3.5 pbw polyethylene
wax (softening point about 120.degree. C.; High Wax 200P; Mitsui Sekiyu
Kagaku K.K.) added as an offset preventing agent.
EXAMPLE 5
A toner was produced in the same manner as described in Example 1 with the
exception that 1.5 pbw polypropylene wax (Biscol 550P; Sanyo Chemicals,
Ltd., softening point about 151.degree. C.) and 2.0 pbw polyethylene wax
(High Wax 200P; Mitsui Sekiyu Kagaku K.K., softening point about
120.degree. C.) were used as offset preventing agents.
EXAMPLE 6
A toner was produced in the same manner as described in Example 1 with the
exception that 1.0 pbw polypropylene wax (Biscol 660P; Sanyo Chemicals,
Ltd., softening point about 145.degree. C.) and 2.5 pbw polyethylene wax
(High Wax 800P; Mitsui Sekiyu Kagaku K.K., softening point about
146.degree. C.) were used as offset preventing agents.
EXAMPLE 7
A toner was produced in the same manner as described in Example 1 with the
exception that 2.0 pbw polypropylene wax (Biscol 550P; Sanyo Chemicals,
Ltd., softening point about 151.degree. C.) and 2.5 pbw polyethylene wax
(High Wax 800P; Mitsui Sekiyu Kagaku K.K., softening point about
146.degree. C.) were used as offset preventing agents.
EXAMPLE 8
A toner was produced in the same manner as described in Example 2 with the
exception that a jet airflow type pulverizer (Model IDS-2 Jet Mill
Pulverizer; Japan Pneumatic, Ltd.) and classifier (Model DS Classifier;
Japan Pneumatic, Ltd.) were used instead of the mechanical pulverizer and
mechanical classifier of Example 2.
EXAMPLE 9
A toner was produced in the same manner as described in Example 1 with the
exception that 1.5 pbw polypropylene wax (Biscol 660P; Sanyo Chemicals,
Ltd., softening point about 145.degree. C.) and 2.5 pbw polyethylene wax
(High Wax 171P; Mitsui Sekiyu Kagaku K.K., softening point about
107.degree. C.) were used as offset preventing agents.
EXAMPLE 10
A toner was produced in the same manner as described in Example 1 with the
exception that 2.0 pbw polypropylene wax (Biscol 550P; Sanyo Chemicals,
Ltd., softening point about 151.degree. C.) and 1.0 pbw polyethylene wax
(High Wax 200P; Mitsui Sekiyu Kagaku K.K., softening point about
120.degree. C.) were used as offset preventing agents.
EXAMPLE 11
A toner was produced in the same manner as described in Example 1 with the
exception that 100 pbw of thermoplastic polyester resin (acid value: 8
KOHmg/g; OH value: 40 KOHmg/g; Tm: 136.degree. C.; Tg: 64.degree. C.) was
used as binder resin.
EXAMPLE 12
A toner was produced in the same manner as described in Example 1 with the
exception that 0.5 pbw polypropylene wax (Biscol 550P; Sanyo Chemicals,
Ltd., softening point about 151.degree. C.) and 2.5 pbw polyethylene wax
(High Wax 200P; Mitsui Sekiyu Kagaku K.K., softening point about
120.degree. C.) were used as offset preventing agents.
EXAMPLE 13
A toner was produced in the same manner as described in Example 1 with the
exception that a jet airflow type pulverizer (Jet Mill model IDS-II; Japan
Pneumatic, Ltd.) and classifier (model DS Classifier; Japan Pneumatic,
Ltd.) were used instead of the mechanical pulverizer and mechanical
classifier of Example 1.
EVALUATIONS
Each of the toners obtained by above-mentioned procedure was evaluated for
the following criteria.
Smear Resistance
Using a copying machine (Model EP9765; Minolta Co., Ltd.), the toners were
fixed to copy sheets, and subsequently the copy sheet on which a copy
image was formed was rubbed against a separate new and unused copy sheet.
The degree of soiling on the new unused copy sheet was observed, and
ranked as shown below.
.smallcircle.: No soiling
.DELTA.: Slight soiling observed, but no practical problem
X: Soiling of entire paper surface
Manufacturing Properties
Manufacturing properties were evaluated by calculating the direct yield of
pulverization and classification processes, and ranking the results as
shown below.
.smallcircle.: Yield of 80% or higher
.DELTA.: Yield of 70% or higher, but less than 80%
X: Yield less than 70%
Toner Scattering Within the Copying Machine
A copying machine (model EP9765; Minolta Co., Ltd.) was used to make 50,000
copies. Toner dispersion within the copying machine and toner spills from
the developing devices were observed, and ranked as described below.
.smallcircle.: No practical problem
.DELTA.: No problem for 10,000 copies, but required maintenance after
50,000 copies
X: Toner dispersion around the developing unit
Fog
When toner scattering within the copying machine was evaluated, toner fog
in the copy images after 50,000 copies was examined, and ranked as
described below.
.smallcircle.: No fog observed
.DELTA.: Slight fogging, but not a practical problem
X: Extensive toner fog
Heat Resistance
Five grams of toner were loaded in an incubator and stored for 24 hr at
50.degree. C., then the measuring container was inverted and the toner
allowed to spill out. The results were ranked as described below.
.smallcircle.: Toner spilled out directly after inverting the container
.DELTA.: Toner spilled out after a little while when the container was
inverted
X: Toner did not spill out of the inverted container
Offset Resistance
The fixing roller temperature was elevated to near 250.degree. C., and
offset was ranked by temperature as described below.
.smallcircle.: No offset even at 250.degree. C.
.DELTA.: Offset above 230.degree. but below 250.degree. C.
X: Offset below 230.degree. C.
TABLE 1
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Mfr
Smear Proper- Scattering Heat Offset
Toner Resistance
ties in Copier
Fog Resistance
Resistance
______________________________________
Ex. 1 .DELTA. .smallcircle.
.smallcircle.
.smallcircle.
.DELTA.
.smallcircle.
Ex. 2 X .smallcircle.
X X .smallcircle.
.smallcircle.
Ex. 3 .DELTA. .smallcircle.
.smallcircle.
.smallcircle.
.DELTA.
.smallcircle.
Ex. 4 .smallcircle.
X .DELTA.
.DELTA.
X X
Ex. 5 .DELTA. .smallcircle.
.smallcircle.
.smallcircle.
.DELTA.
.DELTA.
Ex. 6 .DELTA. .smallcircle.
.smallcircle.
.smallcircle.
.smallcircle.
.DELTA.
Ex. 7 .smallcircle.
.DELTA. .DELTA.
.DELTA.
.smallcircle.
.DELTA.
Ex. 8 X X X X .DELTA.
.smallcircle.
Ex. 9 .DELTA. X .DELTA.
.DELTA.
X .DELTA.
Ex. 10
X .smallcircle.
.smallcircle.
.smallcircle.
.smallcircle.
.DELTA.
Ex. 11
.smallcircle.
X X X X .smallcircle.
Ex. 12
.smallcircle.
.smallcircle.
.DELTA.
.smallcircle.
.DELTA.
.DELTA.
Ex. 13
.DELTA. .smallcircle.
X X .DELTA.
.smallcircle.
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Although the present invention has been fully described by way of examples
with reference to the accompanying drawings, it is to be noted that
various changes and modifications will be apparent to those skilled in the
art.
Therefore, unless otherwise such changes and modification depart from the
scope of the present invention, they should be construed as being included
therein.
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